Post on 05-Jun-2022
INERATEC - Innovative Chemical Reactor Technologies
Manuel Selinsek, Julian Baudner, Paolo Piermartini
Decentralized conversion of Gas-to-Liquid:
Current status on compact FT-Reactors
COMSYN Workshop, 18. – 19. April 2018
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Problem We are Depending on Hydrocarbons Made from Oil and Gas
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Worldwide energy consumption 2035: >55% oil and gas1
Annual CO2 emissions: >35,000,000,000 tons1
1 Statista1
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Technology The Conventional Technology is not Suitable for Renewables
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Solutions Compact Chemical Plants that Produce Renewable Hydrocarbons
Greenhouse Gas Recycling by INERATEC®
Power-to-X
Gas-to-X
Renewable
Fuels and Materials
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Technology USP: Most Compact Chemical Reactor Technology in the World
4 Picture source: ausairpower.net
Scalable
Process simplification
Load flexible
Modular
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Technology INERATEC FT Reactor Technology
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2018
0,0002 bpd
0,05 bpd
0,2 bpd
2 bpd
201520142011
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Technology INERATEC FT Reactor Technology
S. LeViness, FT Product Manager, Presentation "Velocys Fischer-Tropsch Synthesis Technology – Comparison to Conventional FT Technologies”, AIChE Spring Meeting, San Antonio,
Texas/USA (30-Apr-2013)
"2012 Interim Results”, Presentation to analysts of the Oxford Catalysts Group 2012, www.velocys.com
Catalytic activity (C5+ per
catalyst mass)
Reactor productivity
(C5+ per reactor weight)
Space time yield (C5+
per reaction volume)
INERATEC® 2.1 g/gh 16.7 bpd/t 1785 kg/m3h
Velocys* - 13 bpd/t 1600 kg/m3h
Oryx GTL – Sasol - 8 bpd/t 20.6 kg/m3h
Literature Review 1.4 g/gh (Pat.) or
2 g/gh (Lit.)
- -
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
Business Model Engineering, Manufacturing and Sale of Turn-Key Chemical Plants
Engineering Commissioning & Services
Picture Source: INERATEC/VTT
Plant construction
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
COMSYNCompact technology combining centralized and decentralized
processes to develop competitive low carbon energy solutions
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
COMSYNCompact technology combining centralized and decentralized
processes to develop competitive low carbon energy solutions
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
COMSYN Project Goals and FT-Synthesis Tasks
COMSYN Goals:
▪ Compact Gasification and Synthesis Process for Transport Fuels
▪ Production costs for transport fuels < 0,80€/l
▪ Capacity: 30 - 150 MW Feedstock Input, 10 - 50 kt/a FT-product (200 – 1000 bpd)
Main Objectives of the FT-Synthesis:
▪ Testing reactors with purified gas from gasification
▪ Optimizing the operating conditions for maximum paraffin yield
▪ Comparison of single and two-stage synthesis
▪ Design and establishing the manufacture process for reactor modules with 8 bpd size
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
COMSYN Project Goals and FT-Synthesis Tasks
COMSYN Goals:
▪ Compact Gasification and Synthesis Process for Transport Fuels
▪ Production costs for transport fuels < 0,80€/l
▪ Capacity: 30 - 150 MW Feedstock Input, 10 - 50 kt/a FT-product (200 – 1000 bpd)
Main Objectives of the Synthesis Work Package:
▪ Testing reactors with purified gas from gasification
▪ Optimizing the operating conditions for maximum paraffin yield
▪ Comparison of single and two-stage synthesis
▪ Design and establishing the manufacture process for reactor modules with 8 bpd size
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
FT-Synthesis
▪ Exothermic, catalytic reaction (about 165 kJ/mol CO)
▪ T = 210 – 240 °C
▪ p = 15 – 30 bar
General reaction:
𝑛 𝐶𝑂 + 2𝑛 𝐻2 ⇌ 𝑛 𝐶𝐻2 + 𝑛 𝐻2𝑂
→ Predominantly saturated, aliphatic hydrocarbons (C1 – C60+
chains)FT-Products: Liquid and Solid hydrocarbons.
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
FT-Synthesis Microstructured FT-Reactor
Rune Myrstad, Sigrid Eri, Peter Pfeifer, Erling Rytter, Anders Holmen, Catalysis Today,
Volume 147, 2009, Pages S301-S304, https://doi.org/10.1016/j.cattod.2009.07.011.
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
FT-Synthesis Microstructured Lab Scale FT-Reactor
Paolo Piermartini, Tim Boeltken, Manuel Selinsek, Peter Pfeifer, Chemical Engineering
Journal, Volume 313, 2017, Pages 328-335, https://doi.org/10.1016/j.cej.2016.12.076.
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
FT-Synthesis COMSYN 2-Stage Lab Scale Setup
FT
Reactor
Gas dosageH2, CO, CO2, N2
Hot
Trap
FT Wax
Cold
Trap
FT
Reactor
FT Oil,
FT Water
Hot
Trap
FT Wax
Cold
Trap
FT Oil,
FT Water
GC
Bypass
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Picture of 2-Stage FT test rig for COMSYN
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
FT-Synthesis Comparison of single and two-stage synthesis: Initial Experiments
Operation ModeሶVtotal
[Stdml/min]yH2 yCO yCO2 yN2 H2/CO
ptotal[bar]
T[°C]
1-Stage 1226,7 63,5% 33,4% 0% 3,1% 1,9 20 220
1-Stage 613,4 63,5% 33,4% 0% 3,1% 1,9 20220, 230,
240
2-Stage 1226,7 63,5% 33,4% 0% 3,1% 1,9 20220, 230,
240
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INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
FT-Synthesis Comparison of single and two-stage synthesis: Initial Results
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◼ Lab scale setup operational and functional
◼ Applying a 2nd stage leads to
Increased CO and H2 conversion
◼ Intermediate product condensation leads to:
Changes in selectivity
Changed selectivity behavior over temperature
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe
FT-Synthesis COMSYN Reactor Scales
Lab Scale
0,0002 bpd
Pilot Scale
0,05 bpd
Production Scale
8 bpd
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Will be designed in the COMSYN project
INERATEC GmbH – Nördliche Uferstraße 4-6 – 76189 Karlsruhe 19
Thank you for your attention
INERATEC - Innovative Chemical Reactor Technologies
manuel.selinsek@ineratec.de